Method of making floor and roof constructions



April 24, 1951 E. WALTER METHOD OF MAKING FLOOR AND ROOF 'CONSTRUCTIONS a Sheets-Shet 1 Filed Nov. 4, 1947 INVEN rok. [PA/57 14/41 22'? A 7 roe/wry E. WALTER 2,550,627

METHOD OF MAKING FLOOR AND ROOF CONSTRUCTIONSY April 24, 1951 3 Sheets-Sheet 2 Filed Nov. 4, 1947 v INVENTOR. Z 55 fen/57 W417i? w flfTOP/V Y April 24, 1951 E. WALTER METHOD OF MAKING FLOOR AND ROOF CONSTRUCTIONS 3 Sheets-Sheet 3 Filed Nov. 4, 1947 INVENTOR. AA/567' n A/rne Patented Apr. 24, 1951 i'u ii'rnonoFMAKING FLOOR Ernest The present invention is involving concrete beams and slabs.

--It is quiteidesirable insystems ofthis kind toreducethe weight thereof-i while obtaining ade-' quate strength in the concrete elements of which: such structures are formed. eInorderito do ;this,.. it has been common practice to utilize filler blocks which were set upon false flooring and the structural concrete poured between thesame to form beams. Such filler blOCkSFWBIG .often made of alightweight mixture of wood fiber and cement and were produced at a central'pointor factory It was impractical to produce them at the. point of vuse and therefore it..was necessary to. pack such blocks and ship the same. ;Various other types offiller blocks wereused, such as hollow clay tile and concrete tile, which haveflconsiderable strength but such blocks are. fragile and in the handling and transportatioma very substan tial amount of breakage. occurred, Also, it required ,cons iderable careand labor placefthesame in p a 1 .Metal pans or domeshave-.alsobeen used in a .of i l ock Qm t mesth Y e low t rema n.m la eai c the co rete ady set or they were removed. vWhen they were removed, this required extra labor and care-"not, to damage them; in addition, they had to be cleaned, 30 and oiled-again. With metaldomes, it wasnec essary to provide a metal lath ceiling in order to obtain a smooth under-surface when plaster was; applied. a

struction of the'typ'e described wherein all of the filler. blocks and of the structural parts are fabricated in the field and transportation and erection of fragile elements is avoided.

[It is also among the objects invention to provide a method offmaking a lighter structure having improved acoustic properties jv better heatinsulation and a high degreefof flre l resistance.

directed to a method of making mechanical structures 1 such as floor and roof constructions, more particularlythose icp p rly. 1

The present invention is intended and adapted to overcome the difficulties and disadvantagesinherent in prior structures of this type, it being among the objects of the presentinventioriito provide a method of making a floor or. roof con-.-

of the present f I' NSTB QN 7 Walter, 'Montclair, Nil; assignor to-Porete .Manufacturing Company, v North Arlington; d u M N. -J., a corporation of New Jersey Application November 4, IB l'LjSeriaI 11, Claims. (01. 25-155) two-way systems.

AN -B901? ent invention to provide a method of making-'a-- structure of filler blocks which is better adaptable to "various-conditions, 'as spans, loads to be carried, single and continuous designs, -and-one'--or 1 In practicing the present invention, there is provided a false floor form or support, on which there is placed aseries of" box-like forms-which have the shape and arelin the positionofthe beams which 'are to be later formed. After such forms are -in place; there-is provideda highly=' porous, cellular or light concrete mixture which is poured on" the floor between the box-like forms.

' Thisstructure replaces the prior art filler blocks.-

After. the 'porousconcrete has set, .the forms are removed whichlcansbe .readilyaccomplished be.- cause they-are suitably tapereduand-tthen struc-fl tural concretesispoured intotthe: spaces occupied by theforms .wherebythe beams ofthe. structure-"i are .produced and in .thesamecoperationa layer of:.concrete is poured...over;the. entire surface. V i .The porous .concreteused has a-weight which; is not over 50: lbs. per cubicfoot and preferably; the weight is. -from.':15-,to 30 lbs. per. cubic ..foot,.=, Even. lighter; weight, concrete can be; used.;but.,.

theresismianger1 of dama e thereto by theworke,

men treading thereon ,in the-fabrication of. the remainder, of, the structure, ;.The lightweight; concrete is preferably one; in which cement; with or, without a small amount of suitable fiber such as wood fiber,,excelsior, asbestos or the like, is;. mixed it wate a gd a f ami a en u h aspon no the l e. d'po redb n t fo m 91 6.5- O h r m tho s-o t inin cl eh -l;

htmn e e. ybe iu n o w e ce aluminum powder in the thus producing a asizby fi m wkm P mn and an expansion ,'of 39- nqr ,i l erema a b u d, a light aggregateisuch; as vermiculite in the? mc i m xt r -*9. he qre 1 ce lu r n has uniformly dispersed therethrough closed cells T fiud withgas 1dr theic ells beinglusual ly less thanone-eighth inchin diameter, and the concretewill float in, water.

. teris f indicate like parts,

vIt is further amongthe objects of the present invention to providea methodof making a structure of the type described which is relatively simple, which may be readily and quickly erected and which requires workmen of only moderate skill for adequate results.

iii s u u amo t e was or he t e In the accompan in farming comm ting he ra d in w n le e er e hem;

I "1:; Iis a 'fragmentary'perspeetive tiewys m' what j diagrammatic "in nature, illustrating one mode of. operation of the invention;

Fig. Zis-a vertical cross-sectional View taken; along thefline 2-2 of Fig. 1}; J

Fig. 3 is a iew s'ii'nilar to Fi'g. zg hqwmgjme" porous concrete in position and the Fig. 8 is a vertical cross-sectional viewof a structure made with the forms of Figs. 6 or '7';

Fig. 9 is,a view similar to IE-ig...l, .sl- 1owing a modification wherein beamsandcross-beams are formed in the structure;

Fig. is a vertical cross-sectional view of a structure made by a further modification of the box-like forms;

Fig. 11 illustrates the completed structure of Fig. 10;

Fig. 12 is a fragmentary elevational View of a modified form of theinventionshowingdifferent means for retaining the box-like form-son the false floor; I v

fi 1 is a i wisim a to F 's e us a further modification;

Fig. 151 is a detail view of a form of pin used in-the construction of Fig. 13, and

'Fig. is a fragmentary vertical cross-sectional view of a modified form, some parts being shown in elevation.

:Referring to Figs. 1 to 5 inclusive, there is provided a false floor form I held on suitable supports .2 and held in any-desired manner inv position as bybeing supported by walls 3 or by upright members extending from the floor below;

Each of the boxelike forms may consist of side members .4 and 5 tapereddownwardly and in-' wardlyto allow withdrawal thereof from thezconcrete and a bottom member 6 joining the :side members. These forms need not be of uniform width throughout and may be widened as shown at 1 near the walls- 3 to-pro v'ide a greater :crosssection :of' structuralcon'crete tojmore adequately support the load. A series of such 'forms may -'be joined-by end members 8 to complete the'forms and provide spaces 9 between the same. Light weight concreteflo as-described above, is :pouredinto spaces '9 and is allowed to set. Then'the' forms are removed by raising members 4 and 5 which can be withdrawn very readily due to the taper thereof leaving'spaces -l l between blocks '40. Concrete I2 is then poured over block-s I-B filling spaces I I and forming beams l3 which are-suitably supported-on walls '3.

With reference to 'Figss6, '-7-and 8; the box-like forms may be provided with-top'closing' members [4 in order to avoid thepossibility of lightweight concrete accidentally entering the same and also to strengthen the structure-of the form. A'series ofpins or nails 2| driventhroughthe bottom 6 of the forms provides means wherebysaid :forms are supported on floor I out of contact therewith.

"'In Fig. 7 there is shown aimetal form made of sheetmaterialwhere'in thesides lE and lfi are 4 texture. Then the forms of Fig. 6 or 7 are removed, the reinforcing bars [3 are placed into the proper position, and the structural concrete poured in place to form both the floor slabs and the beams in a unitary structure. Plates l9 usually remain in the structure and add reinforcement thereto in addition to the usual reinforc'ements contained in the structural beams.

When both beams and cross beams are to be formed, there is provided a series of box-like forms :4, as shown in Fig. 9, in parallel arrange- ":ment; There are also provided transverse forms having side members 24 and 25 tapering down- ..wardIy and inwardly; the ends thereof being so 15 shaped as to confirm with the sloping sides of for mslc fTransverse end forms have sloping sides tapered downwardly and inwardly'and are integif'al with the bottom. IT. A' metal cover I8 provided over the top and is crimped around the side to complete the form. One or more "plates lihaving legs 20 are placed upon floor-1 and theforms placed on saidplates. When the lightweight concrete is poured in place as shown-in Fig."8,-it' forms blocks '22 "with connecting porftions 23 giving a smooth ceiling and uniform 2.4 and 25 with .oneshaped end conforming with 'form 4 and the other end made in any desired mannerto confirm with the rest of the structure. In making the assembly of forms, 2425 may beset in place, adjacent form ll placed in contact therewith, then form 24-25 placed in contact with'the'same and so .on until all the forms are in place.

Then lightweight concrete is pouredinto a substantially rectangular space 26 to form blocks .21. After they have been set, forms *4 are lifted out, giving access :to forms 24-125 and the like, which may then be removed. This gives :a structure as shown .at the left-hand side of .Fig. 9 having 1ongitudinal spaces :28 .and transverse spaces :29 between blocks '21. Structural concrete is then poured to fill allof the spaces .and also to form aunitary floor'slab.

In Figs. 10 and :11 is shown [3, modification of the invention which eliminates the necessity for false flooring I. "There is provided a series of plates- 30, preferably of metal, which take the place of said floor. Each of the box-like forms :has double sides 3l ---'32 joined at the 'top and diverging'so as toleave the space33 at the lower end thereof and between the same. A-fiange 34 formed on member ill-acts as a support for plate 30. Integral with member '32 is'bottoin 35 complating the false flooring and; this in turn is integral with member efiof the other side of the boxlike form. "Said side also includes a second member 37' integral with 36 and 'diverging therefrom at the bottom'to provide space '38. A flange '39 on member 31 provides means for holding anad jacent plate 30 in position. Such a form maybe supported in any desired manner and is-of sufficient strength so as to carry the dead load of of "the double: side walls together and pulling downwardly, thereby, taking with them the intermediate plates 36. The final structure as shown in' Fig.v 1'1 'may have its iunderside plastered over andithe jspacesdefining the beam will become filled withplaster and giveauniform appearance of ceiling. I

Fig. 12 shows another way of erecting the temporary for rns for the lightweight concretefiller blocks. "By using long steel sheets l and.5, which are benttowards each other .at the bottom as shown Hand, and :tacking these sheets to the false "wood forms with double headed nails: that can be pulled out easily. Thereby, a very simple and adaptable form can be made which caneasily be widened at the ends where required.

,Because the lightweight fill when poured wet weighs about one-half as much as water, the pressure against the sides is very little so that thin sheets may be used.

Fig. 13 shows another way which has been found to be practical for one story buildings where itwouldbe too expensiveto provide special forms. Pins 46, as shown in Fig. 14, have parallel pins 4'! attached to the upper part thereof to form a, slot 48 therebetween. These pins are driven at regular intervals into the false floor. It has been found that alightweight cardboard made ofhigh wet-strength paper which is put into these slots-forms a very adaptable form for the lightweight concrete fill. These paper boards can either be removed when the lightweight concrete fill is set and thrown away, or they may be left in the concrete as a separator between the lightweight and the structural concrete.

There are numerous advantages resulting from the present invention. For instance, the building may be erected much more quickly and ,with less labor than heretofore. and sizes of beams are much more readily produced by the present invention than where precast blocks or a limited number of forms are used. The cost of building a floor or roof according to the present invention is substantially less than by the old methods. The lightweight concrete can be mixed and poured with the use of the same equipment and thesame labor unions as are used in providing the structural concrete. The lightweight concrete made with a foam-producing material does not require special materials or equipment, but utilizes Portland cement with,

, easy'to maintain. They are economical in use in that they may be used over and over again for similar designs of structures.

. If the system described in connection with Figs. 1-0 and 11 is used, the whole floor construction may be made without using any false work and no support from the floor below is necessary. Because of the excellent bond between the lightweight and the structural concrete, the whole structure becomes a unitary mass.

Where a sound absorbing ceiling is necessary and acoustical blocks are used, these may be laid on the false floor and the box-like forms placed thereon, thereby providing as a single unit, an acoustical ceiling and a floor structure. The present type of construction is adapted not only to multi-story buildings but also to one or two floor residences where a fireproof and soundproof first floor over a basement is desired.

Although the invention has been described setting forth several speciiic embodiments thereof, such examples are intended to illustrate the invention and not to limit the same as many varia tions in the details may be made within the spirit of the invention. For instance, the false floor may be supported from the walls, from the lower floor, or otherwise. The materials of construction'may be varied and modified and in some instances such materials as magnesia cement, mixtures containing gypsum and other binders may be used. The several forms may be of suitable material such as Wood, synthetic board, metal and the like and the parts thereof may be foldably assembled or hinged together.

In some cases, as shown in Fig. 15, the boxlike forms may be omitted andthe equivalent Variations in the shape effect-obtained bypouring the lightweight con crete It to a uniform thickness over the entire false floor area I. After the concrete has become set, grooves 52 and 53 for the structural concrete beams may be cut out as with a circular saw or carborundum wheel 56 on shaft 5| and the surplus material 54 removed. The spaces 55 so obtained are in effect box-like forms and the structural concrete is cast into the same, as fully de scribed above.

These and other variations in the detailsof the structure may be'made within the principles herein set forth and the claims are therefore to be broadly construed and not to be limited except by the character of the claims appended hereto.-

I claim:

1. A method of makinga floor or roof structure which comprises erecting a false floor form, plac-. ing thereon longitudinally extending box-like forms of the shape and in the position of the beams .of said structure, pouring a cellular concrete on said floor form between said box-like forms and allowing the same to set, removing said box-f-like forms, pouring structural concrete into the resulting spaces, and allowing the same to set.

2. A method of making a floor or roof structure which comprises erecting a false floor form, placing thereon longitudinally extending box-like forms of the shape and in the position of the beams of said structure, pouring a cellular con-' crete on. said floor form between said box-like forms and allowing the same to set, pouring structural concrete into the resulting spaces, and allowing the same to set.

3. A method of making a floor 'or roof structure which comprises erecting a false floor form, placing thereon longitudinally extending box-like forms of the shape and in the position of the beams of said structure, the bottom of said boxlike forms being above the surface of said fioor form to provide a uniform cast ceilin Pouring a cellular concrete on said floor form between said box-like forms and allowing'the same to set, removing said box-like forms, pouring structural concrete into the resulting spaces, and allowing the same to set.

4. A method of making a floor or roof structure which comprises erecting a false floor form, placing thereon longitudinally extending box-like forms of the shape and in the position of the beams of said structure, pouring a cellular concrete on said floor form between said box-dike forms and allowing the same to set, removing said box-like forms, introducing reinforcing members and then pouring structural concrete into the resulting spaces, and allowing the same to set.

5. A method of making a floor or roof structure which comprises erecting a false floor form, placing thereon longitudinally extending box-like forms of the shape and in the position of the beams of said structure, the sides of said box-like forms being tapered downwardly to facilitate withdrawal thereof after concrete has set, pouring a cellular concrete on said floor form between said box-like forms and allowing the same to set, removing said box-like forms, pouring structural concrete into the resulting spaces, and allowing the same to set.

6. A method of making a floor or roof structure which comprises erecting a false floor form, placing thereon longitudinally extending box-like forms of the shape and in the position of the beams of said structure, pouring a cellular concrete on said floor form between said box-like forms and allowing the same to set, said concrete 7 being a mixture of cement, a foaming agent and water, removing said box-like forms, pouring structural concrete into the resultingspaces, and allowing the same to set.

:7. A meth'od of making floor or roof structure which-comprises erecting a false floor form, pour ing a'cellul'ar concrete on said floor and allowing the same to set, forming longitudinally extending box-like forms of the shape and in the position of the beams of said structure within saidcellular concrete, pouring structural concrete into the resulting spaces, and allowing the same to set.

8. A method of making flooror r structure which comprises-erecting a false floor form, pouring a cellular concrete on said floor and allowing the same to set, forming longitudinally extending box-like forms of the shape and in the position of the beam of said structure Within said cellular concrete by cutting and removing portionso'r said porous concrete, pouring structural concrete into the resulting spaces, and allowing the same to set.

'9. Amethod of making a floor or roof structure which comprises erecting aialsefloor 'form, plac ing thereon longitudinally extending box-like forms of the shape and in the position of the beams of said structure, pouring :a cellular concrete on said floor form between said box-like forms and allowing the same to set, placing reinforcing members into the spaces between said porous concrete elements, pouring structural concrete into the resulting spaces, .and allowing the same to set.

10. A method of making a floor or roof structure which comprises erecting a false fioorform, placing thereon longitudinally extending box-like forms of the shape and in the position of the beams of said structure, pouring a cellular con- 8 crete on said floor :form between said box-like forms and allowing the same to set,removing said box-like forms, placing reinforcing members into the spaces between said porous-concreteelements, pouring structural concrete into the resulting spaces, and allowing the same to set.

11. Amethod of making a floor or roof structure which compriseserectinga false floor form. placing thereon longitudinally extending box-like forms of the shape and in the position of the beams of said structure, pouring a -'cellu1'ar-concrete on said floor form between said box-like forms and allowing the same to set, removing said box-likeforms, pouring structural concrete into the resulting spaces, and allowing the same to set, said box-like forms including vertically placed sheet with means for securing the same to said floor.

ERNEST WALTER.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,137,297 Treo Apr. 27, 1915 1,301,770 Wells Apr. 22, 1919 1,494,538 Gent May 20, 1924 1,597,163 Krump Aug. 24, 1926 1,690,864 Kleitz Nov. 6, 1928 1,869,367 Dean Aug. 2, 1932 2,296,562 Maxwell Sept. 22, 1942 FOREIGN PATENTS Number Country Date 235,006 Great 'Britain June 11, 1925 

